Smart Drive Roll Assembly

ABSTRACT

Systems and methods are provided for manually setting up a wire drive assembly of a welding power supply and automatically setting up welding power supply parameters. A drive roll is configured with multiple grooves for receiving multiple wires of different types and/or different diameters. A sensor can detect the configuration of the drive roll such as, for example, being configured to receive a particular wire type with a particular diameter in a particular groove, by detect a distance to the drive roll. The welding power supply can use this information to automatically set the wire speed.

BACKGROUND

Properly setting up a welding power supply can require the completion ofa number of manual operator tasks that must be performed correctly ifthe welding operation is to succeed.

For example, a welding power supply can be equipped with a wire spooland a drive assembly. The drive assembly can include, for example, adrive roll that must be mounted and correctly set up with the weldingwire from the wire spool based on the wire diameter and/or wire type(e.g., solid wire, flux-cored wire, etc.).

Further, the operator may have to manually set many welding parameterson the power supply including, for example, a workpiece materialthickness, a voltage, a wire speed, and a wire diameter for acorresponding welding operation.

Incorrectly setting up the drive assembly or any of the weldingparameters for the corresponding welding operation can have an adverseeffect on the welding operation.

BRIEF SUMMARY

Systems and methods are provided for setting up a welding power supplyincluding a wire drive assembly substantially as illustrated by and/ordescribed in connection with at least one of the figures, as set forthmore completely in the claims.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 shows top view of a wire drive assembly according to an exampleof the present disclosure.

FIG. 2 shows an angled view of the wire drive assembly shown in FIG. 1.

FIG. 3 shows a perspective view of a drive roll according to an exampleof the present disclosure.

FIG. 4 shows a block diagram illustrating a functionality of the wiredrive assembly according to an example of the present disclosure.

FIG. 5 shows a simplified perspective view of an alternative example ofthe wire drive assembly.

FIG. 6a shows a simplified perspective view of an alternative example ofthe wire drive assembly.

FIG. 6b shows a simplified top down view of the wire drive assembly ofFIG. 6a , illustrating angle detection.

FIG. 7a shows an alternative example wire drive assembly.

FIG. 7b shows a perspective view of an example drive roll carrierreceiving a drive roll in the wire drive assembly of FIG. 7 a.

FIG. 7c is a perspective view of the drive roll carrier of FIG. 7b withthe drive roll disposed on the drive roll carrier.

FIG. 7d is a perspective view of the drive roll carrier of FIG. 7b withthe drive roll secured to the drive roll carrier.

FIG. 7e is a simplified perspective view of the wire drive assembly ofFIG. 7a with a sensor.

DETAILED DESCRIPTION

Preferred examples of the present disclosure may be describedhereinbelow with reference to the accompanying drawings. In thefollowing description, well-known functions or constructions are notdescribed in detail because they may obscure the disclosure inunnecessary detail. For this disclosure, the following terms anddefinitions shall apply.

As utilized herein, “and/or” means any one or more of the items in thelist joined by “and/or”. As an example, “x and/or y” means any elementof the three-element set {(x), (y), (x, y)}. In other words, “x and/ory” means “one or both of x and y”. As another example, “x, y, and/or z”means any element of the seven-element set {(x), (y), (z), (x, y), (x,z), (y, z), (x, y, z)}. In other words, “x, y and/or z” means “one ormore of x, y and z”.

As used herein, the term “processor” means processing devices,apparatuses, programs, circuits, components, systems, and subsystems,whether implemented in hardware, tangibly embodied software, or both,and whether or not it is programmable. The term “processor” as usedherein includes, but is not limited to, one or more computing devices,hardwired circuits, signal-modifying devices and systems, devices andmachines for controlling systems, central processing units, programmabledevices and systems, field-programmable gate arrays,application-specific integrated circuits, systems on a chip, systemscomprising discrete elements and/or circuits, state machines, virtualmachines, data processors, processing facilities, and combinations ofany of the foregoing. The processor may be, for example, any type ofgeneral purpose microprocessor or microcontroller, a digital signalprocessing (DSP) processor, an application-specific integrated circuit(ASIC). The processor may be coupled to, or integrated with a memorydevice.

As utilized herein, the terms “e.g.” and “for example” set off lists ofone or more non-limiting examples, instances, or illustrations.

As used herein, the term “coupled” means attached, affixed, connected,joined, fastened, linked, and/or otherwise secured.

Some examples according to the present disclosure may relate to a wiredrive assembly comprising a drive roll having a plurality ofconfigurations and a sensor configured to detect which of theconfigurations has been set based on a distance to the drive roll.

In some examples, the wire drive assembly may be configured to receive awire having at least one of a wire diameter or a wire type, and thesensor may be configured to detect at least one of the wire diameter orthe wire type based on the distance to the drive roll. In some examples,the drive roll may be configured with a first groove and a secondgroove. The first groove may be configured to receive a first wirehaving a first diameter, and the second groove is configured to receivea second wire having a second diameter. In some examples, the sensor maybe configured to determine whether the drive roll has been set toreceive the first wire having the first diameter or the second wirehaving the second diameter based on the distance to the drive roll. Insome examples, the drive roll may be configured with a first groove anda second groove, and the first groove may be configured to receive afirst type of wire, while the second groove may be configured to receivea second type of wire. In some examples, the sensor is configured todetect whether the drive roll has been set to receive the first type ofwire or the second type of wire based on the distance to the drive roll.In some examples, the first type of wire may be a solid wire, and thesecond type of wire may be a flux-cored wire. In some examples, thedrive roll may have a plurality of slots, and each of the plurality ofslots may correspond to one of the plurality of configurations. In someexamples, the drive roll may be installed on a drive shaft with a pin,and the pin may engage with one of the plurality of slots to set one ofthe plurality of configurations. In some examples, the drive roll may beset at a particular location on the drive shaft when the pin engageswith one of the plurality of slots.

Some examples according to the present disclosure may be related to awire drive assembly, comprising a drive roll with a plurality ofconfigurations relating to receiving different types of wire ondifferent grooves, and a sensor configured to detect which of theconfigurations has been set based on an angle through which the driveroll is rotated in setting one of the plurality of configurations. Someexamples according to the present disclosure may be related to a weldingpower supply comprising a wire drive assembly that includes a drive rollhaving a plurality of configurations, and a sensor configured to detectwhich of the configurations has been set based on a distance to thedrive roll. The welding power supply may further comprise one or moreprocessors operatively coupled to the sensor.

In some examples, the one or more processors may be configured toautomatically determine which of the configurations has been set basedon a signal received from the sensor. In some examples, the drive rollmay be configured to receive different wires with different diameters,and the sensor may be configured to detect the diameter of the wirebased on a distance to the drive roll. In some examples, the one or moreprocessors may be configured to determine the diameter of the wire basedon the signal received from the sensor, and the one or more processorsmay be configured to automatically set a wire speed based on thediameter of the wire. In some examples, the drive roll may be configuredto receive different types of wire, and the sensor may be configured tosense a type of wire based on a distance to the drive roll. In someexamples, the drive roll may be configured with a first groove and asecond groove. The first groove may be configured to receive a firstwire having a first diameter, and the second groove may be configured toreceive a second wire having a second diameter. In some examples, thesensor may be configured to determine whether the drive roll has beenset to receive the first wire having the first diameter or the secondwire having the second diameter based on the distance to the drive roll.In some examples, the drive roll may be configured with a first grooveand a second groove, where the first groove is configured to receive afirst type of wire, and the second groove is configured to receive asecond type of wire. In some examples, the drive roll may have aplurality of slots, and one of the plurality of slots may correspond toone of the plurality of configurations.

FIGS. 1 and 2 show an example of a wire drive assembly 100 according tothe present disclosure from a top view and an angled view, respectively.The wire drive assembly 100 can be coupled to a wire spool (not shown).Further, the wire drive assembly 100 and the wire spool can be part of awelding power supply used in welding operations such as welding, metalinert gas (MIG) welding, gas metal arc welding (GMAW), and/or flux-coredarc welding, for example. However, the present disclosure alsocontemplates that the wire drive assembly 100 can be separate from thewelding power supply or can be used for other applications that use awire drive assembly.

Some examples provide that the wire drive assembly 100 includes, forexample, a housing 110 (e.g., an insulator and/or aluminum drivehousing), a motor 120 (e.g., a gear motor), an inlet wire guide 130, apressure roll lever 140, a pressure adjustment knob 150 (e.g., acalibrated tension knob that is configured to provide consistent wirefeed and/or set drive roll pressure), a drive shaft 160, a retaining pin170, a drive roll 180, a sensor 190 (e.g., a proximity sensor, adistance sensor, a change-in-distance sensor, an angle sensor, achange-in-angle sensor, a movement sensor, an optical sensor, anultrasonic sensor etc.), a T-knob 195 (e.g., welding gun/torch securingknob), and welding gun/torch guides 200.

FIG. 3 shows a perspective view of an example of the drive roll 180according to the present disclosure. The drive roll 180 is configuredwith multiple feed grooves to facilitate quick and easy switchingbetween different welding wire diameters and/or different wire types.Referring to FIG. 3, the drive roll 180 is shown with an exemplary threefeed grooves 210, 220, 230. In some examples, the first feed groove 210is for 0.024″ diameter solid wire; the second feed groove 220 is for0.030″-0.035″ diameter solid wire; and the third feed grove 230 is aV-knurled groove for 0.030″-0.035″ diameter flux-cored wire. The driveroll 180 also has multiple slots 240 that are configured to work withthe retaining pin 170 and the drive shaft 160.

FIG. 4 shows a block diagram illustrating some of the functionality ofthe wire drive assembly 100, according to an example of the presentdisclosure. In the example, the sensor has a functional connection withthe drive roll 180, in that the sensor 190 may detect a configuration ofthe drive roll 180. The sensor 190 also has a functional connection witha processor 400, in that the sensor 190 may communicate the detecteddrive roll 180 configuration to the processor 400. The communication maybe in the form of an electrical signal, for example. The communicationmay be over a communication bus, through a wireless transmission (e.g.radio frequency, Bluetooth, WiFi, LTE, etc.), or through some othersuitable method. The processor 400 may be, for example, a controller, amicrocontroller, a server processor, personal computer processor, alaptop computer processor, a mobile device processor, an applicationspecific instruction set processor (ASIP), a network processor, or anyother suitable processor. The processor 400 may be part of a weldingpower supply and/or in communication with a welding power supply, or maybe separate entirely. When part of the welding power supply and/or incommunication with the welding power supply, the processor 400 may beconfigured to set an appropriate wire speed and/or voltage. In someexamples, the processor 400 may comprise a plurality of processors. Insome examples, the processor 400 may be part of the sensor 190, or thesensor 190 may be part of the processor 400. In some examples, theprocessor 400 and/or sensor 190 may include and/or be in communicationwith a receiver, transmitter, and/or transceiver. In some examples, theprocessor 400 may assist the sensor 190 with its detections and/ordeterminations, and/or vice versa.

To set up the wire drive assembly 100 according to some examples of thepresent disclosure, a wire is pulled from a wire spool, which may or maynot be part of a welding power supply, for example. The wire is guidedthrough the inlet wire guide 130 and through the appropriate groove 210,220, 230 of the drive roll 180. Thus, for example, if the wire is asolid wire with a 0.024″ diameter solid wire, then the wire is fed intogroove 210. If the wire is a flux-cored wire with a 0.035″ diameter,then the wire is fed into the V-knurled groove 230. The wire is then fedinto the liner extending from one end of the welding torch/gun assemblyand passing through the welding gun/torch guides 200. The end of thewelding torch/gun assembly rests against the outer welding gun/torchguide 200 and the welding torch/gun assembly is secured by the T-knob195. The pressure roll lever 140 is moved to a closed position so thatthe wire is properly installed in the appropriate groove 210, 220, 230of the drive roll 180. The pressure adjustment knob 150, which extendsfrom the housing 110 of the wire drive assembly 100, can be brought downagainst the pressure roll lever 140. The pressure adjustment knob 150can then be turned to set the drive roll pressure for consistent wirefeed.

To set up the drive roll 180 before the installation of the wireaccording to some examples of the present disclosure, the drive roll 180has slots 240 (e.g. pockets) that are lined up with the retaining pin170 and pushed over the drive shaft 160. By pushing the drive roll 180towards the wire drive assembly 100 and turning the drive roll 180, theretaining pin 170 can be secured into one of the slots 240. In someexamples, one slot 240 might be used for 0.024″ diameter solid wire; oneslot 240 might be used for 0.030″-0.035″ diameter solid wire; and oneslot might be used for 0.030″-0.035″ diameter flux-cored wire. Byrotating the drive roll 180 into a corresponding slot 240, the driveroll 180 is moved up or down relative to the surface of the housing 110of the wire drive assembly 100 so that the respective groove 210, 220,230 is aligned with the output of the inlet wire guide 130.

Thus, for example, if 0.024″ diameter solid wire is to be fed into thewire drive assembly 100, then the drive roll 180 should be pushed androtated until the retaining pin 170 is secured in the corresponding slot240. The drive roll 180 is configured such that, when the retaining pin170 is secured in the slot 240 corresponding to the 0.024″ diametersolid wire, the drive roll 180 is positioned such that the groove 210configured for use with 0.024″ diameter solid wire is aligned with theinlet wire guide 130 to receive the 0.024″ diameter solid wire that willbe fed from the inlet wire guide 130. If a different wire diameterand/or type of wire is to be used, then the drive roll 180 can be pushedin and turned until the retaining pin 170 is secured in one of the slots240 corresponding to the different wire type and/or wire diameter. Whenthe retaining pin 170 is secured in the selected slot 240, then thegroove 210, 220, 230 corresponding to the different wire is positionedto receive the different wire.

In operation, according to some examples of the present disclosure, thesensor 190 is positioned and/or configured to detect and/or determinewhich diameter of wire and/or type of wire is being fed into the wiredrive assembly 100. The sensor 190 may additionally, or alternatively,be configured to generate and/or transmit a signal that specifies whichdiameter of wire and/or type of wire is being fed into the wire driveassembly 100. In some examples, the sensor 190 may be positioned and/orconfigured to detect and/or determine a distance and/or a change indistance that indicates which slot 240 has been selected to secure theretaining pin 170 and/or which groove 210, 220, 230 has been selected toreceive the incoming wire. Additionally, or alternatively, the sensor190 may be configured to generate and/or transmit a signal specifying adistance and/or a change in distance that can be used to determine whichslot 240 has been selected to secure the retaining pin 170 and/or whichgroove 210, 220, 230 has been selected to receive the incoming wire. Thedistance can be, for example, the distance between the sensor 190 andthe drive roll 180 (e.g., a bottom surface of the drive roll 180); thedistance between a surface of the housing 110 and the drive roll 180;and/or the distance between a predetermined point and the drive roll180.

In some examples, the sensor 190 may be positioned and/or configured todetect and/or determine an angle (e.g., a rotational angle) and/or achange in angle that indicates which slot 240 has been selected tosecure the retaining pin 170 and/or which groove 210, 220, 230 has beenselected to receive the incoming wire. Additionally, or alternatively,the sensor 190 may be configured to generate and/or transmit a signalthat specifies an angle (e.g., a rotational angle) and/or a change inangle that indicates which slot 240 has been selected to secure theretaining pin 170 and/or which groove 210, 220, 230 has been selected toreceive the incoming wire. Thus, turning the drive roll 180 through arotational angle with respect to one or more predetermined referencepoints and/or angles may be used to determine which slot 240 and/orgroove 210, 220, 230 has been selected. The predetermined referencepoint(s) and/or angle(s) may be the slot used when the drive roll 180 isaligned with the retaining pin 170 and pushed on the drive shaft 160,one of the other known slots, the retaining pin 170, a logo and/or othermarking on the drive roll 180, a logo and/or other marking on thehousing 110, and/or an arbitrary reference point or angle.

In some examples, many of the welding parameters (e.g. workpiecematerial thickness, voltage, wire speed, wire diameter, etc.) can bedetermined and set up automatically, rather than manually setting up thedrive roll and manually inputting welding parameters. For example, bysetting up the drive roll for a particular wire with a particulardiameter as described above, the sensor 190 can automatically determinethe type of wire and/or the diameter of the wire. The sensor 190 may bein communication with the welding power supply and/or one or moreprocessors 400 that may or may not be part of the welding power supply.The welding power supply and/or one or more processors 400 mayautomatically determine the appropriate wire speed for the particularwire type and wire diameter as indicated by the sensor 190. In someexamples, the welding power supply and/or one or more processors 400 mayautomatically determine and/or set the appropriate wire speed based atleast in part on the sensor 190 detected wire type and/or wire diameter.In some examples, the wire speed may be determined and/or set based onother variables as well. Then the operator can manually enter aworkpiece material thickness (e.g., by turning a dial or entering anumber) and the welding power supply and/or one or more processors 400can automatically determine the appropriate voltage for the weldingoperation.

With fewer manual parameters that must be input by operators, thedisclosed wire drive assembly 100 and/or welding power supply offersfewer opportunities for manual parameter input errors to occur. Thedisclosed wire drive assembly 100 may also reduce the time needed by anoperator to set up an associated welding power supply. The wire driveassembly 100 may include a sensor to automatically detect theappropriate wire type and/or wire diameter when the wire is installed inthe wire drive assembly 100. Thus, an operator may skip the step ofmanually setting the wire diameter by using a sensor 190 (e.g., aproximity sensor, one or more optical sensors, and/or any other sensorcapable of determining a position of the drive roll 180) to detect thelocation of the drive roll 180 placement on the drive shaft 160 of themotor 120 (e.g., gear motor). The wire diameter and/or the wire speedmay automatically be set when the wire is installed in the wire driveassembly 100. The operator would not have to separately and additionallyinput the wire diameter information (e.g., by turning a knob or enteringnumbers) and/or the wire speed information. In some examples, this mayallow for more space on a front panel of the welding power supply andprovide increased potentiometer resolution that can determine theresolution of wire feed speed of the welding power supply.

Because the retaining pin 170 is located in a consistent place on thelength of the drive shaft 160 and because the slots 240 (e.g., pockets)are at specific depths in the drive roll 180, the retaining pin 170sitting in one of the slots 240 determines which wire diameter settingand/or which type of wire is being set for the drive roll 180. Thesensor 190 can detect a distance, a change in distance, an angle, and/ora change in angle and send a signal to a controller (e.g., one or moreprocessors that may or may not be part of the welding power supply)indicating the wire diameter and/or the type of wire being used. Thecontroller can then automatically determine and set a wire speed, forexample.

FIGS. 5 and 6 show alternative examples of the wire drive assembly 100.The diagrams of FIGS. 5 and 6 are simplified, with some componentsand/or detail omitted. FIG. 5 illustrates a wire drive assembly 500 withan alternative sensor 190 placement. As shown in FIG. 5, the sensor 190may be coupled to a support 502 above and/or spaced from the drive roll180, rather than being coupled to the housing 110. In some examples, thesupport 502 may be part of and/or coupled to the pressure roll lever140. As shown in FIG. 5, the support 502 may include a pillar 504 thatis coupled to the housing 110. An arm 506 of the support 502 may becoupled to the pillar 504. The arm 506 may extend over, adjacent, and/orparallel to the drive roll 180, at a spaced distance from the drive roll180. The sensor 190 may be coupled to the arm 506 via appropriate means(e.g. fastener, screw, magnet, bolt, pin, latch, etc.).

The sensor 190 may be coupled to the arm 506 at a position where thesensor 190 may detect a distance and/or a change in distance between thesensor 190 and/or arm 506 and the drive roll 180. In some examples, thesensor 190 may be positioned such that the sensor 190 detects a distanceD between the sensor 190 and/or arm 506 and a periphery of the driveroll 180, between the slots 240 and an edge of the drive roll 180. Thedetected and/or determined distance D and/or change in distance D may beused to determine which slot 240 and/or groove 210, 220, 230 has beenselected. The sensor 190 may be configured to generate and/or transmit asignal that specifies the distance D and/or a change in distance D thatindicates which slot 240 has been selected to secure the retaining pin170 and/or which groove 210, 220, 230 has been selected to receive theincoming wire. The corresponding wire diameter and/or wire speed mayautomatically be set when the wire is installed in the wire driveassembly 100.

In some examples, the sensor 190 may be coupled to the arm 506 at aposition where the sensor 190 may detect and/or determine an angle(e.g., a rotational angle) A and/or a change in angle A between thesensor 190 and/or arm 506 and the drive roll 180. For example, as shownin FIG. 6a , the sensor 190 may be positioned substantially aligned withthe drive shaft 160. The sensor 190 may detect and/or determine an angleA with respect to one or more predetermined reference points RP and/orangles. For example, a predetermined reference point RP may be the slotused when the drive roll 180 is aligned with the retaining pin 170 andpushed on the drive shaft 160, one of the other known slots, theretaining pin 170, a logo and/or other marking on the housing 110, driveroll, and/or support 502, and/or an arbitrary reference point or angle.FIG. 6b shows an example illustration of the sensor 190 detecting anangle A between two references points RP1 and RP 2. In the example ofFIG. 6b , the first reference point RP1 may be a point at the end of thearm 506, approximately aligned with the center of the arm 506. Thesecond reference point RP2 may be a point on the drive roll 180, such asa slot 290, marking, or some other reference point. The angle A may bedetected and/or determined using the reference points RP1 and RP2. Thedetected and/or determined angle may be used to determine which slot 240and/or groove 210, 220, 230 has been selected. The sensor 190 may beconfigured to generate and/or transmit a signal that specifies an angleA and/or a change in angle A that indicates which slot 240 has beenselected to secure the retaining pin 170 and/or which groove 210, 220,230 has been selected to receive the incoming wire. The correspondingwire diameter and/or wire speed may automatically be set when the wireis installed in the wire drive assembly 100.

In some examples, multiple sensors 190 may be used. For example, onesensor 190 may be positioned on the housing 110, while another sensor190 is positioned on the support 502. In another example, one sensor 190may be positioned on the support 502 to detect an angle and/or a changein angle, while another sensor 190 is positioned on the support 502 todetect a distance from the sensor 190 to the drive roll 180. In anotherexample, one sensor 190 may be positioned on the housing 110 to detectangle, while another sensor 190 is positioned on the housing to detectdistance. A third sensor 190 may be positioned on the support 502 todetect an angle and/or a change in angle, while a fourth sensor 190 ispositioned on the support 502 to detect a distance from the sensor 190to the drive roll 180.

FIGS. 7a through 7e illustrate another alternative example of a wiredrive assembly 700. As shown in FIG. 7a , the wire drive assembly 700may include two drive rolls 780: a first drive roll 780 a and a seconddrive roll 780 b. In some examples, the wire drive assembly 700 mayinclude more than two drive rolls 780, such as three drive rolls 780,four drive rolls 780, six drive rolls 780, etc. Each drive roll 780 maybe supported on a wire drive assembly housing 52. In some examples, thewire drive assembly housing 52 may comprise a drive casting. Both thedrive rolls 780 are configured to rotate with respect to the wire driveassembly housing 52.

The drive assembly 700 may feed welding wire 24 from a spool 30 to awelding application. The first drive roll 780 a may engage with thewelding wire 24, applying a downward force F to the welding wire 24 forfeeding the welding wire 24 between the drive rolls 48 and 50. Thisdownward force F may generate traction between the drive rolls 780 a and780 b, and the welding wire 24, effectively holding the welding wire 24in alignment through a welding wire feed region 64 located between thefeed rolls 48 and 50. As illustrated, the drive roll 780 b is mounted ona clamp arm 66, which may be forced down by a tensioner (and/or pressureadjustment knob) 70. The tensioner 70 may apply a desired amount ofcompressive force F to the clamp arm 66, pushing the drive roll 780 btoward the drive roll 780 a. Adjustment of the compressive force Fapplied by the tensioner 70 may alter the size of the wire feed region64, and the desired compressive force F may be determined based on thediameter and material properties of the welding wire 24 (e.g., steelversus aluminum welding wire).

One or both of the drive rolls 780 a and 780 b may be held within thewire drive assembly 32 via drive roll carriers 54. These drive rollcarriers 54 may allow for relatively easy insertion and removal of thedrive rolls 780 a and 780 b from the wire drive assembly 32. However,the drive roll carriers 54 may also prevent a sensor 190 from beingplaced below the drive rolls 190.

In some examples, these drive rolls 780 a and 780 b may be changed outoccasionally. That is, the drive rolls 780 a and 780 b may be replacedor exchanged for ones configured to accommodate different sizes, types,(e.g. 0.024″ diameter solid wire; 0.030″-0.035″ diameter solid wire;0.030″-0.035″ diameter flux-cored wire) and/or materials of welding wire24 (e.g. steel, aluminum, copper, etc.). In some examples, the driverolls 780 may be removed, reversed, and reinserted to accommodate adifferent wire size, shape, and/or material. For example, the driverolls 780 may include feed grooves 710 and/or 720. In some examples, thefeed groove 710 may be a V-knurled groove for 0.045″ diameter solid wireand the feed groove 720 may be a U groove for 0.030″-0.035″ diametersolid wire and/or flux-cored wire. The drive rolls 780 may be removed,reversed, and reinserted to change from feed groove 710 to feed groove720, and/or vice versa.

The drive roll carriers 54 may include gears 72, as illustrated, forsyncing the rotation of the drive rolls 780 a and 780 b. Even if thedrive rolls 780 a and 780 b themselves do not touch, the gears 72 uponwhich they are mounted may be engaged, such that the motion impartedfrom the motor to the drive roll 48 is also transferred to thecorresponding drive roll 780 b. In some embodiments, multiple sets ofdrive rolls 780 may be arranged on corresponding drive roll carriers 54that are geared together via a gear assembly that receives mechanicalpower from a single motor. While both drive rolls 780 a and 780 b areshown as supported on the drive roll carriers 54, in other examples, onedrive roll 780 a may be supported on the drive roll carrier 54, whilethe other drive roll 780 b may be a static roller that rotates inresponse to the rotation of the nearby drive roll 780 a.

FIG. 7b shows of an example drive roll 780 and drive roll carrier 54. Inthe illustrated example, the drive roll carrier 54 includes the gear 72,a hub 90, drive roll engagement features 92, and a retainer 94. The gear72 is configured to be rotated via the motor of the wire drive assembly700. This rotation occurs about a rotational axis of the gear 72. Therotational axis of the gear 72 may be approximate to that of arrow 134.The hub 90 may be coupled to and extending axially (or longitudinally)from the gear 72. The rotational axis of the gear 72 may also representa longitudinal axis of the hub 90.

Engagement features 92 are configured to engage the drive roll 780 andto urge rotation of the drive roll 780 as the gear 72 is rotated by themotor. The engagement features 92 are dowel pins in the illustratedexample, although other types of engagement features may be used aswell. These engagement features 92 may be coupled to the gear 72,extending axially (or longitudinally) outward from the gear 72 in adirection substantially parallel (e.g., within less than approximately1-2 degrees) to the rotational axis. Although illustrated as having 3engagement features 92, in other examples, there may be any desirablenumber (e.g., 1, 2, 4, 5, 6, or more) of the engagement features 92.

The retainer 94 is configured to be disposed around the hub 90 forretaining the drive roll 780 onto the drive roll carrier 54. Theretainer 94 may include one or more alignment features that can bebrought into or out of alignment with the engagement features 92. In theillustrated embodiment, these alignment features include three lobes 108extending radially outward from the retainer 94. These lobes 108 arelocated approximately every 120 degrees about the outer circumference ofthe retainer 94, just as the engagement features 92 are configured to bedisposed every 120 degrees around the hub 90. In this manner, all threeof the lobes 108 may be brought into alignment with the engagementfeatures 92 at the same time. In addition, the retainer may include oneor more indexing features that align with corresponding indexingfeatures of the hub 90 for locking the retainer 94 into differentpositions relative to the hub 90.

In some examples, the drive roll carrier 54 may be configured tofacilitate loading and securing of the drive roll 780 onto the driveroll carrier 54. Specifically, the retainer 94 may be movable between afirst position where the lobes 108 are aligned with the engagementfeatures 92 and a second position where the lobes 108 are not alignedwith the engagement features 92 (e.g., moved approximately 60 degreesout of alignment from the engagement features 92). To move the retainer94 between these positions relative to the engagement features 92, theretainer 94 may be rotated about hub 90 such that the indexing feature110 of the retainer 94 moves from interfacing with one indexing feature102 to a subsequent indexing feature 102 of the hub 90. This movement ofthe retainer 94 relative to the hub 90 may be accomplished withoutmoving the retainer 94 in a direction substantially parallel to therotational axis 100. That is, the retainer 94 is not moved along thelength or longitudinal axis of the hub 90 when being moved betweendifferent indexed positions.

FIGS. 7c and 7d illustrate the fully assembled drive roll carrier 54receiving, holding, and securing the drive roll 780 so that the driveroll 780 may be rotated as the drive roll carrier 54 is rotated. FIG. 7bis a perspective view of an embodiment of the drive roll carrier 54receiving the drive roll 780. The illustrated drive roll 780 includes abore 730 with three slots 132 protruding radially outward from the bore730. As illustrated, the slots 132 may be circumferentially spaced atapproximately every 120 degrees about the inner circumference of thebore 730. When the drive roll 780 is positioned on the drive rollcarrier 54, the engagement features 92 may engage the slots 132 to urgerotation of the drive roll 780 as the drive roll carrier 54 is rotated.The drive roll 780 may be shaped differently in other examples.

In FIG. 7b , the drive roll carrier 54 is positioned for receiving thedrive roll 780. More specifically, the retainer 94 is positioned aboutthe hub 90 such that the lobes 108 of the retainer 94 are aligned withthe engagement features 92 of the drive roll carrier 54. An operator mayinsert the drive roll 780 onto the drive roll carrier 54, as shown byarrow 134. During insertion, the slots 132 are aligned with both thelobes 108 and the engagement features 92 of the drive roll carrier 54.From the illustrated position, the drive roll carrier 54 may receive thedrive roll 780 via the lobes 108. The lobes 108 may be aligned with theengagement features 92 such that the drive roll 780 can be transitionedfrom resting on the lobes 108 to resting on the engagement features 92and abutting the surface 106 of the gear 72.

Once the drive roll 780 is positioned with the slots 132 resting on theengagement features 92, as shown in FIG. 7c , the retainer 94 may betransitioned from this first position to a second position. In the firstposition, the indexing features 102 and 110 have locked the retainer 94in place relative to the hub 90 such that the lobes 108 are aligned withthe engagement features 92. Once the drive roll 780 is positioned on theengagement features 92, however, it may be desirable to secure the driveroll 780 so that it does not move axially (or longitudinally) withrespect to the drive roll carrier 54. Thus, the retainer 94 may berotated, as shown by an arrow 740, to the next indexing point relativeto the hub 90, in order to secure the drive roll 780 onto the drive rollcarrier 54. As noted above, the retainer 94 may be repositioned viarotation about the hub 90, without being translated in an axial (orlongitudinal) direction along the length of the hub 90.

FIG. 7d shows the drive roll carrier 54 positioned such that the driveroll 780 is secured onto the drive roll carrier 54. The retainer 94 isdisposed in the second position relative to the hub 90 such that thelobes 108 of the retainer 94 are not aligned with the engagementfeatures 92, which are engaged with the slots 132 of the drive roll 780.In the second position, the indexing features 102 and 110 have lockedthe retainer 94 in place relative to the hub 90 such that the lobes 108are in a staggered (or non-aligned) position relative the engagementfeatures 92. Thus, the drive roll 780 cannot slide axially (orlongitudinally) off of the drive roll carrier 54, and the drive roll 780is securely engaged by the drive roll carrier 54. If an operator desiresto remove the drive roll 780, the operator may turn the retainer 94 backto the prior indexing position, or to another indexing position wherethe lobes 108 are aligned with the engagement features 92.

FIG. 7e illustrates the wire drive assembly 700 with a sensor 190. Thediagram of FIG. 7e is simplified, with some components and/or detailomitted. As in FIGS. 5 and 6 a, the sensor 190 may be coupled to asupport 502 above and/or spaced from the drive roll 180, rather thanbeing coupled to the housing 110. As shown in FIG. 5, the support 502may include a pillar 504 that is coupled to the housing 110. In someexamples, the support 502 may be part of and/or coupled to the clamp arm66. An arm 506 of the support 502 is coupled to the pillar 504. The arm506 extends over and/or parallel to the drive roll 180, at a spaceddistance from the drive roll 180. The sensor 190 may be coupled to thearm 506 via appropriate means (e.g. fastener, screw, magnet, bolt, pin,latch, etc.).

In some examples, a recessed groove 508 may be formed on the top of oneor both of the drive rolls 780, and the sensor 190 may be positionedsuch that the sensor 190 detects a distance D between the sensor 190(and/or arm 506) and the groove 708. In some examples, the groove 508may instead be formed as a raised ridge 508, and the sensor 190 may bepositioned such that the sensor 190 detects a distance D between thesensor 190 (and/or arm 506) and the ridge 508. The groove and/or ridge508 may be positioned at a periphery of the drive roll 180, between thelobes 108 and slots 132, and an edge of the drive roll 780. In theexample shown in FIG. 7e , only the drive roll 780 b has a groove/ridge708, while the drive roll 708 a has no groove or ridge.

In some examples, one face and/or side of the drive roll 780 may have agroove, while the other side has a ridge. In some examples, one faceand/or side of the drive roll 780 may have a groove/ridge 508, while theother side has a plain face with no groove/ridge 508. The groove/ridge508 may help identify which groove 710, 720 is in operative use. In thesystem 700, the drive rolls 780 may have to be removed, reversed, andreinstalled in order to change the operative groove from groove 710 togroove 720, and/or vice versa. Thus, without the groove/ridge 508, thedrive roll 780 might always be at the same distance D from the sensor190, regardless of which groove 710, 720 was being used. With agroove/ridge 708 on one side of the drive roll 780, and no groove/ridge708 (or a different depth/height groove/ridge 708) on the other side,the detected and/or determined distance D may be used to determine whichgroove 710, 720 has been selected as the operative groove. In someexamples, each drive roll 780 and/or each face/side of each drive roll780, may have a distance D from the sensor 190 in accordance with thewire size/diameter and/or wire type of its operative groove. The sensor190 may be configured to generate and/or transmit a signal thatspecifies the distance D that indicates which drive roll and/or whichgroove 710, 720 has been selected to receive the incoming wire and thesystem may thereby automatically determine and/or set the appropriatesize/diameter, type, and/or material of the wire.

In some examples, such as shown in FIG. 7e , each drive roll 708 a, 708b may have a sensor 190 coupled to a support 502 for detecting adistance D between the sensor 190 and the drive roll 780. In someexamples, only one drive roll 780 may have a may have a sensor 190coupled to a support 502. In some examples, one drive roll 780 may havea sensor 190 coupled to a support 502, while another has a sensorcoupled to the housing, such as in the weld drive assembly 100. Inexamples where more than one sensor 190 is used, one sensor 190 may beset as the master sensor 190, while one or more other sensors 190 areset as slave sensors 190, such that the configuration detected by themaster sensor 190 may override any conflicting configuration detected bythe slave sensor(s) 190. In some examples, the sensors 190 may beconfigured with different priorities, ranks, and/or grades, such thatone sensor 190 may be master to a second sensor while also being slaveto a third sensor. In some examples, the sensor 190 may be configured todetect and/or recognize certain markings and/or symbols (e.g. a logo,barcode, QR code, ID number, part number, etc.) on the drive roll 780that indicates which drive roll 780 (and/or which side/face of the driveroll 780) is being used, which may in turn indicate what type groove710, 720 is in use, and/or what size/diameter and/or type of wire is inuse.

While the present method and/or system has been described with referenceto certain implementations, it will be understood by those skilled inthe art that various changes may be made and equivalents may besubstituted without departing from the scope of the present methodand/or system. In addition, many modifications may be made to adapt aparticular situation or material to the teachings of the presentdisclosure without departing from its scope. Therefore, it is intendedthat the present method and/or system not be limited to the particularimplementations disclosed, but that the present method and/or systemwill include all implementations falling within the scope of theappended claims.

1. A wire drive assembly, comprising: a drive roll having a plurality ofconfigurations; and a sensor configured to detect which of theconfigurations has been set based on a distance to the drive roll. 2.The wire drive assembly according to claim 1, wherein the drive roll isconfigured to receive a wire having at least one of a wire diameter or awire type, wherein the sensor is configured to detect at least one ofthe wire diameter or the wire type based on the distance to the driveroll.
 3. The wire drive assembly according to claim 1, wherein the driveroll is configured with a first groove and a second groove, wherein thefirst groove is configured to receive a first wire having a firstdiameter, and wherein the second groove is configured to receive asecond wire having a second diameter.
 4. The wire drive assemblyaccording to claim 4, wherein the sensor is configured to determinewhether the drive roll has been set to receive the first wire having thefirst diameter or the second wire having the second diameter based onthe distance to the drive roll.
 5. The wire drive assembly according toclaim 1, wherein the drive roll is configured with a first groove and asecond groove, wherein the first groove is configured to receive a firsttype of wire, and wherein the second groove is configured to receive asecond type of wire.
 6. The wire drive assembly according to claim 6,wherein the sensor is configured to detect whether the drive roll hasbeen set to receive the first type of wire or the second type of wirebased on the distance to the drive roll.
 7. The wire drive assemblyaccording to claim 7, wherein the first type of wire is a solid wire,and wherein the second type of wire is a flux-cored wire.
 8. The wiredrive assembly according to claim 1, wherein the drive roll has aplurality of slots, and wherein each of the plurality of slotscorresponds to one of the plurality of configurations.
 9. The wire driveassembly according to claim 9, wherein the drive roll is installed on adrive shaft with a pin, and wherein the pin engages with one of theplurality of slots to set one of the plurality of configurations. 10.The wire drive assembly according to claim 10, wherein the drive roll isset at a particular location on the drive shaft when the pin engageswith one of the plurality of slots.
 11. A wire drive assembly,comprising: a drive roll having a plurality of configurations relatingto receiving different types of wire on different grooves; and a sensorconfigured to detect which of the configurations has been set based onan angle through which the drive roll is rotated in setting one of theplurality of configurations.
 12. A welding power supply, comprising: awire drive assembly including a drive roll having a plurality ofconfigurations, and a sensor configured to detect which of theconfigurations has been set based on a distance to the drive roll; andone or more processors operatively coupled to the sensor.
 13. Thewelding power supply according to claim 13, wherein the one or moreprocessors are configured to automatically determine which of theconfigurations has been set based on a signal received from the sensor.14. The welding power supply according to claim 14, wherein the driveroll is configured to receive different wires with different diameters,and wherein the sensor is configured to detect the diameter of the wirebased on a distance to the drive roll.
 15. The welding power supplyaccording to claim 15, wherein the one or more processors are configuredto determine the diameter of the wire based on the signal received fromthe sensor, and wherein the one or more processors are configured toautomatically set a wire speed based on the diameter of the wire. 16.The welding power supply according to claim 13, wherein the drive rollis configured to received different types of wire, and wherein thesensor is configured to sense a type of wire based on a distance to thedrive roll.
 17. The welding power supply according to claim 13, whereinthe drive roll is configured with a first groove and a second groove,wherein the first groove is configured to receive a first wire having afirst diameter, and wherein the second groove is configured to receive asecond wire having a second diameter.
 18. The welding power supplyaccording to claim 18, wherein the sensor is configured to determinewhether the drive roll has been set to receive the first wire having thefirst diameter or the second wire having the second diameter based onthe distance to the drive roll.
 19. The welding power supply accordingto claim 13, wherein the drive roll is configured with a first grooveand a second groove, wherein the first groove is configured to receive afirst type of wire, and wherein the second groove is configured toreceive a second type of wire.
 20. The welding power supply according toclaim 13, wherein the drive roll has a plurality of slots, and whereinone of the plurality of slots corresponds to one of the plurality ofconfigurations.